Production method for fire resistant article

ABSTRACT

A method of forming an article is provided. Multi-fiber cellulose strips are interacted with a bonding agent and layered in a plurality of layers, the layered cellulose strips collectively defining opposed major surfaces. A porous sheet member, interacted with a fire-retarding solution, is engaged with one of the major surfaces of the layered cellulose strips, to substantially cover the major surface. The porous sheet member is disposed adjacent to a substantially smooth and uniform surface, and layered cellulose strips and the porous sheet member collectively exposed to an actuating element, configured to actuate the bonding agent to react in a volumetrically-expensive reaction with the fire-retarding solution to facilitate cohesion between the layered cellulose strips and the porous sheet member to form a board member, wherein the porous sheet member conforms to the adjacent surface via the volumetrically-expansive reaction to define a substantially smooth and uniform surface of the board member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is divisional of U.S. patent application Ser. No.15/141,985, filed Apr. 29, 2016 (now U.S. Pat. No. 10,569,502), which isa continuation of International Application No. PCT/CA2014/051044, filedOct. 30, 2014, which International Application was published by theInternational Bureau in English on May 7, 2015, which claims priority toU.S. Provisional Application No. 61/898,200, filed on Oct. 31, 2013,which all are incorporated by reference herein in their entirety.

BACKGROUND OF THE DISCLOSURE Field of the Disclosure

Aspects of the present disclosure relate to methods for forming fireresistant articles and articles made by such methods, and, moreparticularly, to a method for forming a fire resistant article, such asan oriented strand board, and associated article made by such method.

Description of Related Art

It may sometimes be desirable for particular articles or products toexhibit resistance to heat and/or fire. In this regard, one significantimpediment to implementing cellulose products on a widespread basis isthe risk of fire. That is, though cellulose products may be implementedin many different applications, those applications may be precluded bythe apparent lack of fire resistance provided by such celluloseproducts. In some instances, a paperboard product may have afire-retardant product applied thereto, post-formation, to provide somefire resistance capabilities for the paperboard product. That is, anexemplary as-formed paperboard product may have a surface treatment, forexample, a liquid fire retardant, applied thereto (i.e., sprayed on) inorder for the treated product to exhibit at least some fire resistance.In such cases, however, one possible limitation in the treatment of theas-formed paperboard product for fire resistance, particularly with aliquid fire retardant, is achieving an even and consistent treatment ofthat product. More particularly, the result of some fire resistancetreatment processes involving application of a liquid fire-retardant toan as-formed paperboard product may be an uneven or otherwiseinconsistent coverage of the fire retardant with respect to the product.In those instances, the uneven treatment may result in varying levels offire resistance of the treated paperboard product which may, in turn,become a hazard in the event of a fire, which the product is intended toretard or otherwise provide some resistance against. Further, suchtreatment processes may not necessarily be efficient in terms ofapplying the fire retardant to the paperboard product.

In addition, even with as-formed cellulose products treated with aliquid fire retardant, the treated product may not necessarily be heatresistant. That is, even if the as-formed cellulose product, treatedwith a liquid fire retardant, were to be locally fire resistant, theassociated heat may break down the cellulose and allow the fire topenetrate the product.

In some instances, it may also be desirable for certain board productsto define and include a substantially smooth and uniform major surface,for example, for receiving a surface veneer treatment or other aestheticsurface treatment, particularly where such a surface treatment isrelatively thin (i.e., paper or stock, wallpaper, paint, etc.). In suchinstances, if that major surface is not substantially smooth anduniform, any imperfections in the surface of the board product willlikely (and undesirably) print through the thin veneer or other thinaesthetic treatment applied to that surface. That is, any protrusions,depressions, or even wood grain texture, for example, evident on thetreatment-receiving surface of the board product will likely andundesirably show, print, or telegraph through any thin veneer or thinsurface treatment applied to that cellulose board product. In addition,there may exist the risk of non-uniform or otherwise poor adhesion ofthe veneer to the treatment-receiving surface. While the lack of asubstantially smooth and uniform surface may be compensated for, forexample, by smoothing the surface, selecting a more viscous adhesive, orincreasing the thickness/rigidity of the veneer, such measures may bemore costly, the process may be more difficult, and the risk will stillexist for printing of non-uniformities and non-uniform adhesion of theveneer to the surface. One such example of a cellulose board producthistorically lacking such a smooth and uniform major surface is, forexample, oriented strand board (OSB), while examples of cellulose boardproducts generally having such a smooth and uniform surface includes,for example, medium density fiber (MDF) board or particle board. Forsuch reasons, MDF and particle board may be preferred, for example, inthe furniture industry, particularly in instances where a thin veneer isapplied to the cellulose board product. However, MDF and particle boardtend to be more expensive in terms of cost, compared to other celluloseboard products such as OSB.

Thus, there exists a need for a process for evenly and consistentlyapplying a fire retardant, particularly a liquid fire retardant, to acellulose product such as, for example, a paperboard product and/or acellulose board product. In some instances, it may also be desirable toform a cellulose product (i.e., OSB) having a substantially smooth anduniform major surface to facilitate veneer or other surface treatmentapplication, while also providing an enhanced level of heat/fireresistance, and a lower cost compared to other cellulose products havinga substantially smooth and uniform surface (i.e., MDF or particleboard).

BRIEF SUMMARY OF THE DISCLOSURE

The above and other needs are met by aspects of the present disclosure,wherein one such aspect relates to a method of forming an article. Sucha method comprises layering multi-fiber cellulose strips in a pluralityof layers, wherein the cellulose strips are interacted with a bondingagent, and the layered cellulose strips collectively define opposedmajor surfaces. A porous sheet member interacted with a fire-retardingsolution is layered on at least one of the major surfaces of the layeredcellulose strips, such that the porous sheet member substantially coversthe at least one major surface. The porous sheet member is disposedadjacent to a substantially smooth and uniform surface. The layeredcellulose strips and the porous sheet member, collectively, are exposedto an actuating element, with the actuating element actuating thebonding agent associated with the layered cellulose strips to react in avolumetrically-expensive reaction with the fire-retarding solutionassociated with the porous sheet member so as to facilitate cohesionbetween the layered cellulose strips and the porous sheet member, and toform a board member therefrom, with the porous sheet member conformingto the substantially smooth and uniform surface disposed adjacentthereto, via the volumetrically-expansive reaction between the poroussheet member and the layered cellulose strips, such that the at leastone major surface having the porous sheet member engaged therewithdefines a substantially smooth and uniform surface of the board member.

The bonding agent may comprise, but is not limited to, urea-formaldehyde(UF), melamine-modified urea-formaldehyde resin (MUF), a phenolic resin,a wax, or methylene diphenyl diisocyanate (MDI). The actuating elementto which the layered cellulose strips and the porous sheet member areexposed may comprise pressure, heat, humidity, heated air, heated humidair, steam, microwave energy, or infrared energy. The porous sheetmember may comprise a kraft paper, an encasement paper, a cellulosepaper, a glass fiber sheet, a glass fiber scrim, a sheet comprising acombination of cellulose fibers and glass fibers, a veneer sheet, aporous sheet in which component fibers thereof treatable with thefire-retarding solution, a paper stock, a card stock, or combinationsthereof.

The fire-retarding solution may comprise a boron compound, a phosphoruscompound, a chlorine compound, a fluorine compound, an antimonycompound, a borate compound, a halogen compound, boric acid, aninorganic hydrate, a bromine compound, aluminum hydroxide, magnesiumhydroxide, hydromagnesite, antimony trioxide, a phosphonium salt,ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide,bromochlorodifluoromethane, dibromotetrafluoroethane,dibromodifluoromethane, carbon tetrachloride, urea-potassiumbicarbonate, or combinations thereof. Generally, the fire-retardingsolution may comprise an aqueous fire-retarding solution, a nontoxicliquid fire-retarding solution, or a neutral pH liquid fire-retardingsolution. That is, in particular aspects, the fire-retarding solutionmay be an aqueous fire-retarding solution, or it may be preferred thatthe fire-retarding solution be nontoxic and/or have a neutral pH and/orbe hypoallergenic and/or have any number of otherwise desirableproperties. In some aspects, a mold inhibitor, a water resistancetreatment, and/or an insect deterrent may be interacted with the poroussheet member, the fire-retarding solution, the cellulose strips, and/orthe bonding agent prior to exposing the layered cellulose strips and theporous sheet member to the actuating element. The insect deterrent maycomprise glass particles and/or a borate substance, for providing atermite deterrent.

The cellulose strips may be layered such that the cellulose stripsdefining each of the opposed major surfaces have the fibers thereoforiented along a strength axis of the board member. Further, at least aportion of the cellulose strips not defining either of the opposed majorsurfaces may have the fibers thereof oriented perpendicularly to thestrength axis of the board member. In some instances, the layeredcellulose strips and the porous sheet member may be deposited into amold arrangement having the substantially smooth and uniform surfaceprior to exposing the layered cellulose strips and the porous sheetmember to the actuating element. In other instances, the layeredcellulose strips and the porous sheet member may be deposited in athermal press and exposed to an actuating element comprising pressure,heat, humidity, heated air, heated humid air, steam, microwave energy,and/or infrared energy, to form the board member.

The present disclosure thus includes, without limitation, the followingembodiments:

Example Implementation 1

A method of forming an article, said method comprising layeringmulti-fiber cellulose strips in a plurality of layers, the cellulosestrips being interacted with a bonding agent, and the layered cellulosestrips collectively defining opposed major surfaces; layering a poroussheet member, the porous sheet member being interacted with afire-retarding solution, on at least one of the major surfaces of thelayered cellulose strips, such that the porous sheet membersubstantially covers the at least one major surface; disposing theporous sheet member adjacent to a substantially smooth and uniformsurface; and exposing the layered cellulose strips and the porous sheetmember, collectively, to an actuating element, the actuating elementactuating the bonding agent associated with the layered cellulose stripsto react in a volumetrically-expensive reaction with the fire-retardingsolution associated with the porous sheet member so as to facilitatecohesion between the layered cellulose strips and the porous sheetmember, and to form a board member therefrom, with the porous sheetmember conforming to the substantially smooth and uniform surfacedisposed adjacent thereto, via the volumetrically-expansive reactionbetween the porous sheet member and the layered cellulose strips, suchthat the at least one major surface having the porous sheet memberengaged therewith defines a substantially smooth and uniform surface ofthe board member.

Example Implementation 2

The method of any preceding embodiment, or any combination of precedingembodiments, further comprising engaging a bonding agent with thecellulose strips, the bonding agent comprising urea-formaldehyde (UF),melamine-modified urea-formaldehyde resin (MUF), a phenolic resin, awax, or methylene diphenyl diisocyanate (MDI).

Example Implementation 3

The method of any preceding embodiment, or any combination of precedingembodiments, wherein layering the cellulose strips further compriseslayering the cellulose strips such that the cellulose strips definingeach of the opposed major surfaces have the fibers thereof orientedalong a strength axis of the board member.

Example Implementation 4

The method of any preceding embodiment, or any combination of precedingembodiments, wherein layering the cellulose strips further compriseslayering the cellulose strips such that at least a portion of thecellulose strips not defining either of the opposed major surfaces havethe fibers thereof oriented perpendicularly to the strength axis of theboard member.

Example Implementation 5

The method of any preceding embodiment, or any combination of precedingembodiments, further comprising depositing the layered cellulose stripsand the porous sheet member into a mold arrangement prior to exposingthe layered cellulose strips and the porous sheet member to theactuating element, the mold arrangement including the substantiallysmooth and uniform surface.

Example Implementation 6

The method of any preceding embodiment, or any combination of precedingembodiments, wherein exposing the layered cellulose strips and theporous sheet member to the actuating element further comprises exposingthe layered cellulose strips and the porous sheet member to theactuating element including pressure, heat, humidity, heated air, heatedhumid air, steam, microwave energy, or infrared energy.

Example Implementation 7

The method of any preceding embodiment, or any combination of precedingembodiments, wherein exposing the layered cellulose strips and theporous sheet member to an actuating element further comprises exposingthe layered cellulose strips and the porous sheet member to at least oneof pressure, heat, humidity, heated air, heated humid air, steam,microwave energy, and infrared energy, in a thermal press, to form theboard member.

Example Implementation 8

The method of any preceding embodiment, or any combination of precedingembodiments, wherein layering the porous sheet member on at least one ofthe major surfaces further comprises layering the porous sheet membercomprising a kraft paper, an encasement paper, a cellulose paper, aglass fiber sheet, a glass fiber scrim, a sheet comprising a combinationof cellulose fibers and glass fibers, a veneer sheet, a porous sheet inwhich component fibers thereof treatable with the fire-retardingsolution, a paper stock, a card stock, or combinations thereof, on atleast one of the major surfaces of the layered cellulose strips.

Example Implementation 9

The method of any preceding embodiment, or any combination of precedingembodiments, further comprising interacting the porous sheet member withthe fire-retarding solution, the fire-retarding solution comprising aboron compound, a phosphorus compound, a chlorine compound, a fluorinecompound, an antimony compound, a borate compound, a halogen compound,boric acid, an inorganic hydrate, a bromine compound, aluminumhydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, aphosphonium salt, ammonium phosphate, diammonium phosphate, methylbromide, methyl iodide, bromochlorodifluoromethane,dibromotetrafluoroethane, dibromodifluoromethane, carbon tetrachloride,urea-potassium bicarbonate, or combinations thereof.

Example Implementation 10

The method of any preceding embodiment, or any combination of precedingembodiments, further comprising interacting the porous sheet member withthe fire-retarding solution, the fire-retarding solution comprising anaqueous fire-retarding solution, a nontoxic liquid fire-retardingsolution, or a neutral pH liquid fire-retarding solution.

Example Implementation 11

The method of any preceding embodiment, or any combination of precedingembodiments, further comprising interacting a mold inhibitor, a waterresistance treatment, or an insect deterrent with the porous sheetmember, the fire-retarding solution, the cellulose strips, or thebonding agent prior to exposing the layered cellulose strips and theporous sheet member to the actuating element.

These and other features, aspects, and advantages of the presentdisclosure will be apparent from a reading of the following detaileddescription together with the accompanying drawings, which are brieflydescribed below. The present disclosure includes any combination of two,three, four, or more features or elements set forth in this disclosure,regardless of whether such features or elements are expressly combinedor otherwise recited in a specific embodiment description herein. Thisdisclosure is intended to be read holistically such that any separablefeatures or elements of the disclosure, in any of its aspects andembodiments, should be viewed as intended, namely to be combinable,unless the context of the disclosure clearly dictates otherwise.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the disclosure in general terms, reference willnow be made to the accompanying drawings, which are not necessarilydrawn to scale, and wherein:

FIG. 1 schematically illustrates an exemplary specimen of an orientedstrand board comprised of multi-fiber cellulose strips;

FIG. 2 schematically illustrates adjacent layers of an oriented strandboard, wherein the cellulose strips and/or the cellulose fibers thereofin adjacent layers are generally orthogonally arranged with respect toeach other;

FIG. 3A schematically illustrates adjacent layers of an oriented strandboard, wherein the cellulose strips and/or the cellulose fibers thereofin adjacent layers are generally orthogonally arranged with respect toeach other, with the cellulose strips being interacted with a bondingagent, according to aspects of the present disclosure;

FIGS. 3B and 3C schematically illustrate adjacent layers of an orientedstrand board, wherein the cellulose strips and/or the cellulose fibersthereof in adjacent layers are generally orthogonally arranged withrespect to each other, with the cellulose strips being interacted with abonding agent, and at least one of the major surfaces being engaged witha porous sheet member, according to aspects of the present disclosure;

FIGS. 4A and 4B schematically illustrate various arrangements forinteracting a porous sheet member with a fire-retarding solution,according to aspects of the present disclosure;

FIG. 5 schematically illustrates adjacent layers of an oriented strandboard, wherein the cellulose strips and/or the cellulose fibers thereofin adjacent layers are generally orthogonally arranged with respect toeach other, with the cellulose strips being interacted with a bondingagent, and at least one of the major surfaces being engaged with aporous sheet member, wherein the components are received by an exemplaryarrangement for exposure to an actuating element, according to aspectsof the present disclosure; and

FIG. 6 schematically illustrates a method of forming an article,according to aspects of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allaspects of the disclosure are shown. Indeed, the disclosure may beembodied in many different forms and should not be construed as limitedto the aspects set forth herein; rather, these aspects are provided sothat this disclosure will satisfy applicable legal requirements. Likenumbers refer to like elements throughout.

Aspects of the present disclosure are generally directed to a fireresistant sheathed article or product, such as an oriented strand board(OSB), and a production method associated with such an article. As such,one aspect of the present disclosure involves a method of forming anarticle. In general, as shown in FIG. 1, an oriented strand board 100 isformed by layering multi-fiber cellulose strips 200 in a plurality oflayers. Such multi-fiber cellulose strips 200 may vary considerably inactual dimensions and configurations, as will be appreciated by oneskilled in the art. Accordingly, such cellulose strips 200 may beconsidered as, for example, strands, flakes, chips, strips, or othermulti-fiber elements, or combinations thereof, from a cellulose (i.e.,wood) source. For example, such cellulose strips 200, as implementedherein, may be on the order of up to 1 inch wide by up to 6 inches longand up to 0.25 inches in thickness, in contrast to more refinedcellulose fibers or particles which are used, for example, in othercellulose board products, such as MDF or particle board. However,recitation of multi-fiber cellulose strips herein does not necessarilysignify that other more refined fibers may be excluded from the subjectarticle. Of course, the article could, in some aspects, compriseexclusively cellulose strips of the type defined herein. In otherinstances, the article could include some amount of more refinedcellulose fibers, in addition to the cellulose strips. In still otherinstances, other fibers, such as glass fibers, could be used instead of,or in addition to, the refined cellulose fibers. However, in somepreferred instances, the article includes a majority (i.e., >50%) of thecellulose strips as defined herein. In yet other instances, one skilledin the art will appreciate that the article disclosed herein iscomprised primarily of cellulose including, though not necessarily, upto being comprised exclusively cellulose, but at least comprising amajority of cellulose, and does not include compositions whereincellulose strips of the type defined herein are added in minor portionsto an article primarily comprised of a non-cellulose material. Oneskilled in the art will also appreciate that, though aspects of thepresent disclosure are described in relation to an oriented strand board(OSB), that the inventive aspects of the present disclosure may also besimilarly applicable to the production of other types of cellulose boardarticles/products such as, for example, medium density fiber (MDF) boardor particle board, and, as such, the scope of the present disclosure isnot intended to be limiting in this regard.

In order to form a sheet of OSB, the cellulose strips 200 may be layeredsuch that the cellulose strips in the layers defining each of theopposed major surfaces have the fibers 250 thereof oriented generallyalong a strength axis 275 of the board member 100 (see, e.g., FIG. 2).That is, for example, a sheet of OSB may be provided in a rectangularconfiguration (i.e., 4 feet by 8 feet), wherein it may be desirable forthe OSB sheet to have resistance to flexing along the major dimension(i.e., along the 8 foot long dimension of the surface). In such aninstance, the cellulose strips 200 in the surface layers 300A, 300C ofthat OSB sheet may be oriented so as to generally have the fibers 250extending along the 8 foot dimension of the OSB sheet, as the strengthaxis 275 thereof. One skilled in the art will appreciate, however, thatthe strength axis 275 could also be oriented along the 4 foot longdimension of the OSB sheet, and the fibers 250 of the cellulose strips200 in the surfaces layers 300A, 300C could be oriented to extend alongthe 4 foot dimension of the OSB board. Further, in some instances, atleast a portion of the cellulose strips 250 not defining either of theopposed major surfaces may have the fibers 250 thereof orientedperpendicularly to the strength axis 275 of the board member. That is,the OSB sheet may include one or more other (medial) layers 300B ofcellulose strips 200 between the two surface layers 300A, 300C. Thosemedial layers 300B may have the cellulose strips 200 oriented such thatthe fibers 250 thereof are oriented generally perpendicularly to thesurface layer. Of course, if the OSB sheet includes a plurality ofmedial layers, the medial layers may be alternated so as to include aplurality of layers with the fibers of the cellulose strips thereofaligned in parallel with the strength axis, and a plurality of layerswith the fibers of the cellulose strips thereof aligned perpendicularlyto the strength axis. In some aspects, the overall board member (i.e.,OSB) may be configured to have a plurality of layers of cellulosestrips, wherein the fibers of cellulose strips in each layer areoriented generally perpendicularly to the fibers of the cellulose stripsin the adjacent layer(s) through the thickness of the OSB sheet (see,e.g., FIG. 3A).

In particular aspects of the present disclosure, the layered cellulosestrips collectively define opposed major surfaces 150A, 150B (see, e.g.,FIG. 3A), with the thickness of the layered cellulose strips comprisingthe third dimension of the board/article. In forming the board/article,the layered cellulose strips may also include a bonding agent 350(schematically shown, e.g., in FIG. 3A). The bonding agent 350 maycomprise, for example, any one of urea-formaldehyde (UF),melamine-modified urea-formaldehyde resin (MUF), a phenolic resin, awax, and methylene diphenyl diisocyanate (MDI), or any variouscombinations thereof. The bonding agent 350 may be added to or otherwiseinteracted with the layered cellulose strips in various manners. Forexample, each of the cellulose strips could be coated, treated, orotherwise interacted with the bonding agent prior to forming the layeredarrangement. In other instances, in addition to or in the alternative tothe treatment of each cellulose strip with the bonding agent, thebonding agent could, for example, be deposited between layers of thecellulose strips as the cellulose strips are being layered.

According to particular aspects of the present disclosure, once thecellulose strips 200, interacted with the bonding agent 350, arelayered, a porous sheet member 400 may be interacted or otherwiseengaged with at least one of the major surfaces 150A, 150B of thelayered cellulose strips 200, such that the porous sheet member 400substantially covers the at least one major surface (see, e.g., FIGS. 3Band 3C, each of which has the bonding agent 350 omitted for the purposesof clarity, though it is expressly understood that such aspects do, infact, include the bonding agent 350 as previously disclosed andillustrated in FIG. 3A). That is, the porous sheet member 400 may beconfigured to extend substantially over the exposed lateral area of thelayer of cellulose strips 200 defining one of the major surfaces 150A,150B defined by the collective layers of cellulose strips (i.e., 300A,300B, 300C). The porous sheet member 400 may comprise, for example, asheet member comprising a kraft paper, an encasement paper, generallyany cellulose or cellulose-based paper, a glass fiber sheet, a glassfiber scrim, a porous sheet comprising any combination of cellulose andglass fibers (i.e., 0% glass fibers up to 100% glass fibers), a veneersheet, and/or any porous sheet in which component fibers can be treatedwith the fire-retarding solution, though any relatively thin grade ofpaper stock or card stock may be sufficient and appropriate in regard tothe aspects of the disclosure herein. In particular aspects of thepresent disclosure, the porous sheet member 400 is treated, engaged, orotherwise interacted with a fire-retarding solution 450 (see, e.g.,FIGS. 4A and 4B), prior to the porous sheet member 400 being applied tothe at least one major surface of the layered cellulose strips. Forexample, the fire-retarding solution 450 may be added to and dispersedin the cellulose fiber pulp used to form the porous sheet member. Inother instances, the as-formed porous sheet member 400 may be immersedin or otherwise saturated with the fire-retarding solution. For example,the as-formed porous sheet member could be immersed in a container ofthe fire-retarding solution (see, e.g., FIG. 4B), could be exposed to ashower or other significant volumetric flow of the fire-retardingsolution, or could be exposed to a uniform mist or spray of thefire-retarding solution (see, e.g., FIG. 4A) for a period sufficient tothoroughly and uniformly treat the porous sheet member with thefire-retarding solution. In some aspects, if necessary or desired, themulti-fiber cellulose strips may also be treated or otherwise interactedwith the fire-retarding solution, in addition to the porous sheetmember.

The fire-retarding solution 450 may comprise, for example, one of aboron compound, a phosphorus compound, a chlorine compound, a fluorinecompound, an antimony compound, a borate compound, a halogen compound,boric acid, an inorganic hydrate, a bromine compound, aluminumhydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, aphosphonium salt, ammonium phosphate, diammonium phosphate, methylbromide, methyl iodide, bromochlorodifluoromethane,dibromotetrafluoroethane, dibromodifluoromethane, carbon tetrachloride,urea-potassium bicarbonate, and combinations thereof. More generally,however, the fire-retarding solution may comprise one of an aqueousfire-retarding solution, a nontoxic liquid fire-retarding solution, anda neutral pH liquid fire-retarding solution. That is, in particularaspects, the fire-retarding solution may be an aqueous fire-retardingsolution, or it may be preferred that the fire-retarding solution benontoxic and/or have a neutral pH and/or be hypoallergenic and/or haveany number of otherwise desirable properties or combinations thereof.For example, it may be preferred that the fire-retarding solution benontoxic and/or have a neutral pH and/or be hypoallergenic and/or haveany number of otherwise desirable properties in regard to human/animaland/or environmental safety, while maintaining the necessary efficacy,as implemented and upon exposure to heat and/or flame. In this regard,one skilled in the art will appreciate that various fire-retarding orfire/heat resistant substances, either currently known or laterdeveloped or discovered, may be applicable to the disclosed processesand articles herein within the scope of the present disclosure. Oneskilled in the art will further appreciate that the fire-retardingsolution may be formed by adding a solid fire-retardant product to aliquid (i.e., water) or other chemical.

In some aspects, a mold inhibitor, a water resistance treatment, and/oran insect deterrent may be interacted with the porous sheet memberand/or the fire-retarding solution, but also may be interacted with thecellulose strips and/or the bonding agent, during arrangement of thelayered cellulose strips and the porous sheet member (or, in any event,prior to the formation of the board member therefrom upon exposure to anactuating element). The insect deterrent may comprise, for example, oneof glass particles and a borate substance, for providing a termitedeterrent.

Once arranged, the layered cellulose strips 200 (including the bondingagent 350) and the porous sheet member 400 are collectively exposed toan actuating element, wherein the actuating element is configured toactuate the bonding agent 350 so as to facilitate cohesion of thelayered cellulose strips 200 and the porous sheet member 400, and toform a board member 100 therefrom. That is, the actuating element maypreferably be configured to promote actuation of the bonding agent 350,in order for the bonding agent 350 to exhibit the necessary efficacy forfacilitating cohesion between the layered cellulose strips 200 and theporous sheet member 400, by way of the bonding agent. The actuatingelement, in some aspects, facilitates the formation of the layeredcellulose strips (including the bonding agent) and the porous sheetmember into the board member, wherein, in particular aspects, the atleast one major surface having the porous sheet member engaged therewithis substantially smooth and uniform (i.e., the resulting surface of theboard product is substantially smooth and uniform by conforming to asubstantially smooth and uniform surface adjacent thereto during theresponse to the actuating element). In particular aspects, anappropriate actuating element may comprise, for example, pressure, heat,humidity, heated air, heated humid air, steam, microwave energy, and/orinfrared energy, and/or combinations thereof. In one instance, thelayered cellulose strips (including the bonding agent) and the poroussheet member are collectively exposed to an actuating element comprisingpressure 600 and heat 650 (see, e.g., FIG. 5). In such instances, thelayered cellulose strips (including the bonding agent) and the poroussheet member may be deposited into a mold arrangement 625 prior to beingexposed to the actuating element or, in other instances, the layeredcellulose strips (including the bonding agent) and the porous sheetmember may be, for example, directly deposited in a thermal press(wherein the mold arrangement 625 may comprise an element of the overallthermal press and, thus, both the mold arrangement and thermal press aregenerally referred to herein by element number 625, wherein the moldarrangement/thermal press 625 may include, for example, a heated-platenpress) for exposure to the actuating element. In addition, once actuatedby the actuating element to facilitate cohesion between the layeredcellulose strips and the porous sheet member, the bonding agent may alsopromote some desirable characteristics exhibited by the board membersuch as, for example, a degree of water resistance (i.e., reduced oreliminated “swelling” of the board member if exposed to water).

According to some aspects of the present disclosure, the interactionbetween the bonding agent associated with the cellulose strips and thefire-retarding solution associated with the porous sheet member, in thepresence of sufficient moisture, may cause the formation of avolumetrically-expanding substance, or may otherwise result involumetric expansion of the mixture. In an unconstrained interaction,such a mixture may result in a volumetrically-expanding foam substance.Once expanded, however, the resulting mixture may undergo a curing orhardening process, whereby the expanded material (mixture) solidifiesand hardens. Accordingly, aspects of the present disclosure achieve thesubstantially smooth and uniform property of the major surface havingthe porous sheet member engaged therewith through such interaction. Thatis, the bonding agent associated with the cellulose strips interactingwith the fire-retarding solution associated with the porous sheetmember, in the presence of sufficient moisture, for example, from thecellulose strips and/or bonding agent, when constrained by the moldarrangement/thermal press, may result in the formation of theaforementioned volumetrically-expanding substance. Thevolumetrically-expanding substance may have sufficient reactivity orother properties to cause the volumetrically-expanding substance and/orthe porous sheet member to conform to the (usually) smooth and uniformsurface of the platen(s) defining the mold arrangement/thermal press,and potentially to fill any voids or non-uniformities between the poroussheet member and the layered cellulose strips. The presence of heat alsoassociated with the mold arrangement/thermal press serves to facilitatethe hardening/curing process for the volumetrically-expanding substanceso as to fix or set the major surface of the board product (having theporous sheet member engaged therewith), following removal of the boardproduct from the mold arrangement/thermal press.

Further, in some aspects, the mold arrangement and/or thermal press maybe configured to receive the layered cellulose strips, the bondingagent, and the porous sheet member, prior to the layered cellulosestrips, the bonding agent, and the porous sheet member being exposed tothe actuating element, wherein the mold arrangement/thermal press 625may be further configured to facilitate exposure of the layeredcellulose strips, the bonding agent, and the porous sheet member to theactuating element. For example, where the actuating element comprisesheated air, humidity, steam, or heated humid air, the moldarrangement/thermal press 625 may include a porous element 675 having anactuating element source (e.g., element 700 in FIG. 5 representing asource of heat and/or humidity/steam) in communication therewith. Oncethe layered cellulose strips, the bonding agent, and the porous sheetmember (collectively element 800 as shown, for example, in FIG. 5) aredeposited in the mold arrangement/thermal press 625, the actuatingelement from the actuating element source 700 may be directed thereto soas to enter the mold arrangement/thermal press 625 through the porouselement 675 so as to interact with the layered cellulose strips, thebonding agent, and the porous sheet member 800 therein. Permeation ofthe actuating element through the layered cellulose strips, the bondingagent, and the porous sheet member, actuates the bonding agent tofacilitate cohesion/adhesion of the cellulose strips in the variouslayers to form the board member 100. In some aspects, the moldarrangement/thermal press 625 may further include a pressure applicationaspect (see, e.g., element 725 in FIG. 5, for example, a platen of aheated platen press) for applying pressure to the layered cellulosestrips, the bonding agent, and the porous sheet member, while thelayered cellulose strips, the bonding agent, and the porous sheet memberare exposed to the actuating element. Accordingly, one skilled in theart will appreciate that the density of the board member may varyconsiderably, as necessary or desired.

In summary and as shown in FIG. 6, one aspect of the present disclosuremay include a method of forming an article. Such a method compriseslayering multi-fiber cellulose strips in a plurality of layers, thecellulose strips being interacted with a bonding agent, and the layeredcellulose strips collectively defining opposed major surfaces (element900); engaging a porous sheet member, the porous sheet member beinginteracted with a fire-retarding solution, with at least one of themajor surfaces of the layered cellulose strips, such that the poroussheet member substantially covers the at least one major surface(element 925); and exposing the layered cellulose strips and the poroussheet member, collectively, to an actuating element, wherein theactuating element is configured to actuate the bonding agent so as tofacilitate cohesion of the layered cellulose strips and the porous sheetmember, and to form a board member therefrom, and wherein the at leastone major surface cooperates with the porous sheet member engagedtherewith, in response to the actuating element, such that the poroussheet member forms a substantially smooth and uniform surface (element950).

Another aspect of the present disclosure relates to an articleassociated with the production method(s) disclosed herein (see, e.g.,FIG. 3A-3C), wherein such an article comprises a plurality of layers ofmulti-fiber cellulose strips, the layered cellulose strips 200collectively having opposed major surfaces 150A, 150B, and a bondingagent 350 interacted with the cellulose strips 200. A porous sheetmember 400 having a fire-retarding solution 450 interacted therewith isengaged with at least one of the major surfaces of the layered cellulosestrips so as to substantially cover the at least one major surface. Theporous sheet member 400 is configured to cooperate with at least one ofthe layered cellulose strips 200 and the bonding agent 350 such that theat least one major surface having the porous sheet member engagedtherewith defines a substantially smooth and uniform surface of a boardmember 100 formed therefrom, in response to exposure of the cellulosestrips, the bonding agent, and the porous sheet member, collectively, toan actuating element configured to actuate the bonding agent so as tofacilitate cohesion of the layered cellulose strips and the porous sheetmember to form the board member therefrom. According to such aspects,the porous sheet member 400, when engaged with the layered cellulosestrips and upon exposure to the actuation element, may facilitate,contribute to, enhance, or otherwise provide structural properties(i.e., tensile strength, bending resistance, impact resistance, etc.)for the resulting board member 100, particularly if engaged with bothmajor surfaces 150A, 150B thereof. Such structural enhancement may bemore apparent in instances of the board member being relatively thin.Further, the porous sheet member 400 may provide a more suitable,substantially smooth and uniform surface for the resultingarticle/product, for accepting paints, stains, veneers, or other surfacetreatment for enhancing the aesthetic properties of the end product. Oneskilled in the art will appreciate, however, that though the sheetmember is referred to herein in some aspects as being comprised of acellulose material, any other suitable material or combination ofmaterials exhibiting the desired properties disclosed herein may also bedesirable and capable of being implemented within the scope of thepresent disclosure, and as otherwise disclosed herein.

Further, in some aspects of the present disclosure, a board productformed in accordance with the disclosed production method(s) may alsoexhibit other desirable and enhanced properties over those ofconventional particles or products (i.e., conventional OSB). Forexample, such board products may exhibit “zero ignition” and/or “zeroflame spread,” particularly due to the porous sheet member(s) on themajor surface(s) being treated with the fire-retarding solution. In someinstances, by treating only the porous sheet member with thefire-retarding solution (which does not preclude the cellulose stripsand/or the bonding agent from being treated, combined, or otherwiseinteracted with the fire-retarding solution), lower cost and productioncomplexity may be realized. In another example, treatment of the poroussheet member with the fire-retarding solution may achieve a more uniformand thorough dispersion and distribution of the fire-retarding solution,such that the resulting fire/heat resistant sheathing provided by theporous sheet product may otherwise enhance the fire resistance (flamespread), as well as thermal barrier (thermal resistance/insulation)characteristics of the resulting board product, which may avoid the needto treat the entire board product with the fire-retarding solution.

Many modifications and other aspects of the disclosures set forth hereinwill come to mind to one skilled in the art to which these disclosurespertain having the benefit of the teachings presented in the foregoingdescriptions and the associated drawings. For example, the generalcellulose element concept (i.e., the resulting board member) may beapplicable where the general cellulose element is provided as acomponent or other portion of a further end assembly. Particularly, thegeneral cellulose element as disclosed herein may be, for example,included in a process for manufacturing laminated flooring or coredcabinetry. One skilled in the art will thus appreciate that a boardproduct in accordance with aspects of the present disclosure may beproduced such that surface sheathing (porous sheet member) consistentlyand uniformly incorporates the fire-retarding solution. As such, thecomponents of the end assembly comprising the fire-retardant sheathedboard product may likely be wholly resistant to fire and/or unable toignite on a more permanent basis (i.e., since the fire-retardingsolution is effectively integrated into the cellulose product), at leastby way of the major surface having the porous sheet member engagedtherewith, as compared to simple surface treatments that may be easilyremoved, washed away, or subject to degradation over time.

In still other aspects, for example, the mold arrangement/thermal press,or any platen or adjacent surface implemented to form the componentsinto the board product may not necessarily have a smooth and uniformsurface to which the major surface having the porous sheet memberconforms. That is, the platen/adjacent surface may be configured to havea particular texture (i.e., a “textured mold”) such as, for example, awood grain texture or any other desired texture or combinations thereof,wherein the negative of such a texture is formed in the porous sheetmember interacted with the major surface. The volumetrically-expansivereaction between the fire-retarding solution associated with the poroussheet member and the bonding agent associated with the layered cellulosestrips causes the porous sheet member to be pressed into conformity withthe texture of the platen/adjacent surface, thereby imparting a negativeof that texture to the porous sheet member upon hardening/curing so asto permanently retain the negative of the texture in the surface of theresulting board or other product or article. In such instances, theunderlying cellulose strips or engagements therebetween, voids, or othernon-uniformities are still limited or prevented from printing ortelegraphing through the surface sheet member. Therefore, it is to beunderstood that the disclosures are not to be limited to the specificaspects disclosed and that modifications and other aspects are intendedto be included within the scope of the appended claims. Althoughspecific terms are employed herein, they are used in a generic anddescriptive sense only and not for purposes of limitation.

That which is claimed:
 1. A method of forming an article, said methodcomprising: layering multi-fiber cellulose strips in a plurality oflayers, the cellulose strips being interacted with a bonding agent, andthe layered cellulose strips collectively defining opposed majorsurfaces; layering a porous sheet member, the porous sheet member beinginteracted with a fire-retarding solution, on at least one of the majorsurfaces of the layered cellulose strips, such that the porous sheetmember substantially covers the at least one major surface; disposingthe porous sheet member adjacent to a substantially smooth and uniformsurface; and exposing the layered cellulose strips and the porous sheetmember, collectively, to an actuating element, the actuating elementactuating the bonding agent associated with the layered cellulose stripsto react in a volumetrically-expensive reaction with the fire-retardingsolution associated with the porous sheet member so as to facilitatecohesion between the layered cellulose strips and the porous sheetmember, and to form a board member therefrom, with the porous sheetmember conforming to the substantially smooth and uniform surfacedisposed adjacent thereto, via the volumetrically-expansive reactionbetween the porous sheet member and the layered cellulose strips, suchthat the at least one major surface having the porous sheet memberengaged therewith defines a substantially smooth and uniform surface ofthe board member.
 2. The method according to claim 1, further comprisingengaging a bonding agent with the cellulose strips, the bonding agentcomprising urea-formaldehyde (UF), melamine-modified urea-formaldehyderesin (MUF), a phenolic resin, a wax, or methylene diphenyl diisocyanate(MDI).
 3. The method according to claim 1, wherein layering thecellulose strips further comprises layering the cellulose strips suchthat the cellulose strips defining each of the opposed major surfaceshave the fibers thereof oriented along a strength axis of the boardmember.
 4. The method according to claim 1, wherein layering thecellulose strips further comprises layering the cellulose strips suchthat at least a portion of the cellulose strips not defining either ofthe opposed major surfaces have the fibers thereof orientedperpendicularly to the strength axis of the board member.
 5. The methodaccording to claim 1, further comprising depositing the layeredcellulose strips and the porous sheet member into a mold arrangementprior to exposing the layered cellulose strips and the porous sheetmember to the actuating element, the mold arrangement including thesubstantially smooth and uniform surface.
 6. The method according toclaim 1, wherein exposing the layered cellulose strips and the poroussheet member to the actuating element further comprises exposing thelayered cellulose strips and the porous sheet member to the actuatingelement including pressure, heat, humidity, heated air, heated humidair, steam, microwave energy, or infrared energy.
 7. The methodaccording to claim 1, wherein exposing the layered cellulose strips andthe porous sheet member to an actuating element further comprisesexposing the layered cellulose strips and the porous sheet member to atleast one of pressure, heat, humidity, heated air, heated humid air,steam, microwave energy, and infrared energy, in a thermal press, toform the board member.
 8. The method according to claim 1, whereinlayering the porous sheet member on at least one of the major surfacesfurther comprises layering the porous sheet member comprising a kraftpaper, an encasement paper, a cellulose paper, a glass fiber sheet, aglass fiber scrim, a sheet comprising a combination of cellulose fibersand glass fibers, a veneer sheet, a porous sheet in which componentfibers thereof treatable with the fire-retarding solution, a paperstock, a card stock, or combinations thereof, on at least one of themajor surfaces of the layered cellulose strips.
 9. The method accordingto claim 1, further comprising interacting the porous sheet member withthe fire-retarding solution, the fire-retarding solution comprising aboron compound, a phosphorus compound, a chlorine compound, a fluorinecompound, an antimony compound, a borate compound, a halogen compound,boric acid, an inorganic hydrate, a bromine compound, aluminumhydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, aphosphonium salt, ammonium phosphate, diammonium phosphate, methylbromide, methyl iodide, bromochlorodifluoromethane,dibromotetrafluoroethane, dibromodifluoromethane, carbon tetrachloride,urea-potassium bicarbonate, or combinations thereof.
 10. The methodaccording to claim 1, further comprising interacting the porous sheetmember with the fire-retarding solution, the fire-retarding solutioncomprising an aqueous fire-retarding solution, a nontoxic liquidfire-retarding solution, or a neutral pH liquid fire-retarding solution.11. The method according to claim 1, further comprising interacting amold inhibitor, a water resistance treatment, or an insect deterrentwith the porous sheet member, the fire-retarding solution, the cellulosestrips, or the bonding agent prior to exposing the layered cellulosestrips and the porous sheet member to the actuating element.